Method and plant for the production of profiled tubes

ABSTRACT

The method comprises:
         a step, in which all the processing data are set;   a step, in which the processing cycle is processed with one or more processing steps;   a step, in which the processing cycle is controlled, which consists in controlling the rotation of a tube ( 2 ) around its longitudinal axis and the contact of the outer face of the tube ( 2 ) with at least one tool ( 18  and  31 ) along part or the entire longitudinal length of the tube ( 2 ), while performing a continuous or timed comparison of the result reached during the processing cycle; and   a step in which the end of the processing cycle is signaled if the final configuration of the profiling (corrugation or deformation) of the tube  2  is detected.

TECHNICAL FIELD

The present invention relates to a method for the production of profiledtubes.

The present invention also relates to a plant for the production ofprofiled tubes.

The tubes may be either metallic or not. “Profiled tubes” means tubeswhich are either corrugated or deformed according to given conditions.

BACKGROUND ART

As known, the use of profiled tubes is expanding ever more in varioussectors from heating systems to the food processing industry.

Rolling machines are currently marketed in which the rolls are providedarranged around a tube which translates and in contact with the outersurface of the tube itself. Furthermore, the rolls may rotate around thelongitudinal axis of the tube. A plastic deformation of the tube isobtained by effect of such a contact.

The main drawbacks of the currently marketed machines is in that it isnot possible to execute a high number of mutually different deformationor corrugation profiles and in that it is not possible to vary thedeformation of corrugation profile of the tube during processing.

DISCLOSURE OF INVENTION

It is the object of the present invention to make a method forprocessing profiled tubes which is free from the aforesaid drawbacks.

It is a further object of the present invention to make a system forprocessing profiled tubes which is easy to use and allows to make aplurality of deformation or corrugation profiles also on the sameprocessed tube.

According to the present invention, a method for processing profiledtubes (corrugated or deformed tubes) is provided, characterized in thatit comprises:

-   -   a first step, in which all the processing data are set, such as        the final configuration to be obtained, the type of material of        which said tube is made, and the dimensional data of said tube;    -   a second step, in which the processing cycle is processed in one        or more processing steps;    -   a third step, in which the processing cycle is controlled, and        which consists in controlling the rotation of said tube around        its own longitudinal axis and the contact of the outer face of        said tube with at least one tool along part or the entire        longitudinal length of said tube, while performing a continuous        or timed comparison of the result obtained and/or reached during        the processing cycle; and    -   a fourth step, in which the end of processing cycle is        controlled based on what was detected during the comparison        and/or if the final configuration of the profiling (corrugation        or deformation) of said tube is detected.

According to the present invention, a system for processing profiledtubes (corrugated or deformed tubes) is also provided, characterized inthat it comprises:

-   -   a working surface, which is defined on a horizontal plane;    -   first means to support a tube along said working surface;    -   second means, which are suited to determine the rotation of said        tube around its own longitudinal axis;    -   at least one first organ, which is defined by a first tool and        by a first device, which is suited to control the translation of        said tool against said tube until it comes into contact with the        latter; and    -   third means, which are suited to determine the translation of        said first organ along an axis that is parallel to the        longitudinal axis of the tube.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the invention, an embodiment will bedescribed by way of non-limitative example only, with the aid of thefigures of the accompanying drawings, in which:

FIGS. 1 and 2 show a side view and a plan view of a system forprocessing the profiled tubes, respectively;

FIG. 3 is a partial plan view on enlarged scale of a part of the systemin FIGS. 1 and 2;

FIG. 4 is a front view of the part of the system shown in FIG. 3;

FIG. 5 is a partial plan view on enlarged scale of a part of the systemin FIGS. 1 and 2 with different organs from those shown in FIG. 3;

FIG. 6 is a front view of the part of the system shown in FIG. 5;

FIG. 7 is a partial, perspective view of the part of the system shown inFIG. 3;

FIG. 8 is a partial, perspective view of the part of the system shown inFIG. 5;

FIG. 9 is a flow-chart of a control unit of the system in FIGS. 1 and 2;and

FIG. 10 is a flow-chart of the operation of the system in FIGS. 1 and 2.

BEST MODE FOR CARRYING OUT THE INVENTION

As shown in FIGS. 1 and 2, reference numeral 1 indicates as a whole asystem for processing profiled tubes 2, where “profiled tubes” meanstubes on which a deformation or a corrugation is performed. The system 1comprises a base 3 having a working surface 4, defined on a horizontalplane and a plurality of supporting legs 5 of the working surface 4. Thesystem 1 further comprises a first head 6 fitted on a first longitudinalend of the working surface 4 and suited to block a first longitudinalend of the tube 2, and a second head 7 fitted near the secondlongitudinal end of the working surface 4 and suited to block a secondlongitudinal end of the tube 2; the tube 2 has a horizontal longitudinalaxis parallel to the longitudinal axis of the working surface 4. Thehead 6 is a vice (not shown) applied to the first longitudinal end ofthe tube 2. The head 7 is a vice (not shown) carried by a carriage 8suited to translate along the longitudinal axis of the working surface4.

As explained below, the processing of the tube 2 causes a variation ofits longitudinal length, so that the head 7 translates from and towardsthe head 6, and this translation indicates the linear deformation towhich the tube 2 is subjected. The head 6 is provided with a motor 9which determines the rotation around the longitudinal axis of the tube 2and thus the rotation of the tube 2. The head 7 is idly fitted so as notto obstruct the rotation of the tube 2.

The system 1 comprises a second carriage 11, carried by the workingsurface between the heads 6 and 7 and suited to translate along ahorizontal axis parallel to the longitudinal axis of the tube 2. Thecarriage 11 comprises a plate 12 defined on a plane horizontal to anupper level of the working surface 4. The system 1 comprises drive meansof the carriage 11 which, in this embodiment are represented by twoguides 14 arranged along the working surface 4 parallel to thelongitudinal axis of the latter, by shoes 15 carried by the lower wallof the plate 12 (FIGS. 4 and 6) and in contact with a respective guide14, and by a motor 16 (FIGS. 1 and 2) suited to control the translationof the carriage 11 along the longitudinal axis of the working surface 4.

One or more tools according to the conformation to be obtained may beused in order to obtain the profiling (corrugation or deformation) ofthe tube 2. In FIGS. 3, 4 and 7, the carriage 11 supports an organ 17defined by a tool 18 (a roll, in this case) and by a device 21 suited tocontrol the translation of the tool 18 against the tube 2. Obviously,the axis along which the tool 18 translates is horizontal andperpendicular to the longitudinal axis of the tube 2. In use, while thetube 2 rotates around its own longitudinal axis, the contact between thetool 18 and the outer face of the tube 2 determines a deformation of thetube 2. Furthermore, since the carriage 11 translates, the contactbetween the tool 18 and the tube 2 occurs on the entire outer face ofthe tube 2 or for the entire longitudinal length thereof. It is apparentthat multiple passages of the tool 18 in contact with the tube 2 areneeded to gradually confer the preferred shape to the tube 2.

During profiling, the length of the tube 2 varies (shortening orelongating) and thus the carriage 8 is substantially either recalledtowards the head 6 or distanced from the head 6. The displacement of thecarriage 8 is detected by a sensor 22 (diagrammatically shown) for thepurposes which will be illustrated below. Furthermore, during profiling,the tube 2 undergoes a deformation along its own rotation axis (twistingon itself) in either the positive or the negative sense; deformationwhich is detected by a sensor (diagrammatically shown). In order to keepthe tool 18 in contact with the outer face of the tube 2, thetranslation of the tool 18 towards the tube 2 must be controlled bymeans of the device 21. The translation and the correct position of thetool 18 are subordinated to the measures detected by the sensors 22 and23. Substantially, the measures detected the sensors 22 and 23 indicatewhether the obtained dimensions are those selected or if there aredeformations which were not selected but which are due to the materialof the tube 2 is made. In order to avoid bending of the tube 2 duringthe processing, the carriage 11 supports, on the opposite part of theorgan 17, a second organ 24 defined by a contrast tool 25 (a set square,in this case) and a device 26 suited to control the translation of thetool 25 against the tube 2. Obviously, the axis along which the tool 25translates is the same translation axis as the tool 18. The organ 24 isprovided with a sensor 27 (diagrammatically shown) suited to detect thedeformation of the tube 2.

In FIGS. 5, 6 and 8, the organs 17 and 24 are provided with two tools 31defined by a respective roll and devices 21 and 26 which determine notonly the translation the tools 31 but also the angle of the rotationaxis of the rolls. In such a manner, the tools 31 with angle differentfrom its rotation axis cause a deformation of the section of the tube 2to confer an elliptical conformation to the latter (FIG. 6), and alsodetermine a profiling (corrugation or deformation) of the outer face ofthe tube 2.

The system 1 described above may be provided with further devices whichmay improve and substantially make processing more efficient and allowto carry out such a processing in a shorter time. For example, it ispossible to provide the system 1 with a device 41 (diagrammaticallyshown) suited to warm up the tube 2 during its processing so as to makeits processing more efficient. Furthermore, the carriage 11 may beprovided with more organs 17 and 24 arranged mutually side by side; eachorgan 17 and 24 has a tool thereof in contact with the outer face of thetube 2. For example, during the processing of the tube 2, a first organ17 makes a first deformation and the second organ 17 confers a morepronounced deformation with respect to the first. Obviously, the samesolution will be used also for the organs 24. It is apparent that thesecond deformation may be made only for some sections along the entirelength of the tube 2 so as to make a tube 2 which has sections withmutually different profiling (corrugations or deformations). Obviously,instead of the variant described above, the system 1 could be providedwith several carriages 11, each with its own organs 17 and 24. In adifferent variant of the system 1, each organ 17 and 24 is provided withan automatic tool change device so as to reduce times if a tool changeis needed for the same tube 2 being processed or for processing adifferent tube 2.

With reference to FIGS. 1 and 9, the system 1 is provided with anelectronic control unit 51 for all the organs, devices and motorsinstalled in the system 1.

The control unit 51 comprises:

-   -   a unit 52, in which the data for the processing of the tube 2        according to different possible configurations of the profiling        (corrugation or deformation) are stored;    -   a data setting unit 53, in which the operator can select a        profiling (corrugation or deformation) configuration stored or        set a new configuration;    -   a data processing unit 54 to process the data necessary to        process the tube 2;    -   a control unit 55 to control the different organs, devices and        motors installed in the plant 1;    -   a unit 56, which receives the data and the measures detected        during the processing cycle; and    -   a displaying unit 57 to display the selected or set profiling        (corrugation or deformation) configuration and the measures        detected during the processing cycle of the tube 2.

With reference to FIG. 10, the operating cycle of the system 1 includesa start of processing block 61, from which is reached a block 62, inwhich the initial positioning of all the organs and the devicesinstalled in the system 1 is controlled and in which the operation ofall the organs and devices to start the processing cycle is controlled.Block 62 is followed by a block 63, in which the method detects whetherthe obtained deformations are those selected or whether there aredeformations which are not selected but which are due to the material ofwhich the tube 2 is made. Block 63 is followed by a block 64, in whichthe profiling obtained in the tube 2 is compared with the profilingobtained from those selected. If it is detected that the selectedprofiling is obtained, the method goes from block 64 to an end of cycleblock 65, while in the opposite case the method goes from block 64 to ablock 66, and from here back to block 62. All the data of a newprocessing cycle are controlled in block 66 and substantially therepositioning of all the organs and devices installed in the system 1 iscontrolled. If a tool change is needed during the processing cycle,block 64 compares the profiling obtained with that to be obtained in agiven step of the processing cycle. If a second processing step isrequired for processing with a different tool from that of block 64, themethod goes to a block 67 in which the method detects whether all theprocessing steps have ended. In the positive case, from block 67 wearrive to end of cycle block 65, while in the negative case from block67 we arrive to block 68 in which the tool change, which may be eithermanual or automatic, as shown above, is controlled. From block 68 wearrive back to block 62.

The method which is the object of the present invention for processingprofiled tubes (corrugated deformed) comprises:

-   -   a first step, in which all the processing data are set, such as        the final configuration to be obtained, the type of material of        which said tube 2 is made, the diameter of the tube 2, the        thickness of the tube 2, the length of the tube 2;    -   a second step in which whether the final configuration to be        obtained is already stored or to be processed is checked;    -   a third step, in which the processing cycle is processed with        one or more processing steps;    -   a fourth step, in which the tools to be used for all or part of        the processing cycle are selected;    -   a fifth step, in which the processing cycle is controlled and a        continuous or timed comparison of the results reached during the        processing cycle is performed; and    -   a sixth step, in which the end of the processing cycle is        signaled if the final configuration of the profiling of the tube        2 is detected.

A variant of the system 1 could include an automatic loading andunloading of the tube 2 from the system 1. In this case, the system 1 isprovided with a loading and unloading device and the control unit 51 issuited to control such a loading and unloading device.

The advantages obtained by implementing the present invention areapparent and numerous.

In particular, a system and a method for processing profiled tubes(corrugated deformed) is made from which an endless plurality ofprofiling configurations (corrugation or deformation) may be obtained.Additionally, with the system 1 it is possible to obtain a tube 2 whichhas sections with different profiling (corrugation or deformation). Asapparent, the system 1 is easy to produce and may be entirely automaticallowing a shorter processing time, and thus a consequent reduction ofprocessing costs.

1. A method for the production of profiled tubes (2) (corrugated ordeformed tubes), characterized in that it comprises: a first step, inwhich all the processing data are set, such as the final configurationto be obtained, the type of material of which said tube (2) is made, andthe dimensional data of said tube (2); a second step, in which theprocessing cycle is processed with one or more processing steps; a thirdstep, in which the processing cycle is controlled and which consists incontrolling the rotation of said tube (2) around its own longitudinalaxis and the contact of the outer face of said tube (2) with at leastone tool (18 and 31) along part of the longitudinal length of said tube(2) or along the entire longitudinal length of said tube (2), whileperforming a continuous or timed comparison of the result obtainedand/or reached during the processing cycle; and a fourth step, in which,based on what has been detected during the comparison and/or if thefinal configuration of the profiling (corrugation or deformation) ofsaid tube (2) has been detected, the processing cycle is caused to end.2. A method according to claim 1, characterized in that an intermediatestep is provided between said first and second step, during which theoperator checks whether the final configuration to be obtained isalready stored in a memory unit (52) or has to be processed in aprocessing unit (54).
 3. A method according to claim 1, characterized inthat an intermediate step is provided between said second and thirdstep, during which the operator selects the tools to be used for part ofthe processing cycle or for the entire processing cycle.
 4. A plant forthe production of profiled tubes (2) (corrugated or deformed tubes),characterized in that it comprises: a working surface (4), which isdefined on a horizontal plane; first means (6 and 7) to support a tube(2) along said working surface (4); second means (9), which are suitedto determine the rotation of said tube (2) around its own longitudinalaxis; at least one first organ (17), which is defined by a first tool(18, 31) and by a first device (21), which is suited to control thetranslation of said tool (18, 31) against said tube (2) until it comesinto contact with the latter; and third means (16), which are suited todetermine the translation of said first organ (17) along an axis that isparallel to the longitudinal axis of the tube (2).
 5. A plant accordingto claim 4, characterized in that it comprises at least one second organ(24), which is defined by a second contrast tool (25) and by a seconddevice (26), which is suited to control the translation of said secondcontrast tool (25) against said tube (2) until it comes into contactwith the latter; said second organ (24) being supported by a firstcarriage (11), which is moved by said third means (16) and also supportssaid first organ (17), and said second contrast tool (25) being coaxialto said first tool (18) and being arranged on the opposite side withrespect to said tube (2).
 6. A plant according to claim 4, characterizedin that it comprises at least one second organ (24), which is defined bya third tool (31), which is equal to said first tool (31), and by asecond device (26), which is suited to control the translation of saidthird tool (31) against said tube (2) until it comes into contact withthe latter; said second organ (24) being supported by a first carriage(11), which is moved by said third means (16) and also supports saidfirst organ (17), and said third tool (31) being coaxial to said firsttool (31) and being arranged on the opposite side with respect to saidtube (2).
 7. A plant according to claim 4, characterized in that itcomprises fourth means (22, 23 and 27), which are suited to detect theprofiling (corrugation or deformation) defined on said tube (2) duringthe processing cycle.
 8. A plant according to claim 4, characterized inthat it comprises fifth means (41), which are suited to warm up thesection of said tube (2) while the latter is being processed.
 9. A plantaccording to claim 4, characterized in that it is provided with anelectronic control unit (51) comprising: a unit (52), in which the datafor the processing of said tube (2) according to different possibleconfigurations of the profiling (corrugation or deformation) are stored;a data setting unit (53), in which the operator can select a profiling(corrugation or deformation) configuration stored or set a newconfiguration and set the dimensional data of said tube (2); a dataprocessing unit (54) to process the data necessary to process said tube(2); a control unit (55) to control the different organs, devices andmeans installed in the plant; a unit (56), which receives the data andthe measures detected during the processing cycle; and a displaying unit(57) to display the profiling (corrugation or deformation) configurationselected or set and the measures detected during the processing cycle ofsaid tube (2).